Underwater pool light

ABSTRACT

An underwater pool light comprises: a housing; a lens sealingly fixed to the housing; a light source located within the housing; and mounting means for mounting the housing to a niche within or on a wall of a pool. The housing includes an integral connector for external connection to an electrical supply cable, and the pool light includes electrical connection means within the housing connecting the light source to the integral connector.

The present invention relates to an underwater pool light. Inparticular, but not exclusively, the invention relates to disposableunderwater pool lights for use in swimming pools and spa baths,hereafter referred to as “pools”.

Pools are conventionally built in one of four manners. The first methodis to provide two spaced shutters formed from wood or steel, with steelreinforcing bars arranged between the shutters. Apertures are providedat a number of locations in one of the shutters and a niche for the poollight is located in each of the apertures. Typically, the niche ispositioned such that a gap exists between the shutter and a flangemember provided on the niche. Typically, conventional niches have to bemodified so that they are fixed to the shutter by fastening, usually byscrewing, a portion of the niche to the shutter. For steel shutters,which are typically hired from a supplier, the cost of repairing orreplacing the shutter is incurred.

Cement is poured between the shutters and allowed to set and then theshutters are removed. Finishers are then applied to the cement wall,including between the cement wall and flange of the niche. The finisherscomprise render, adhesive and tiling, and the thickness of the finisherscan range from 5 to 45 millimetres. It is a difficult task, given thisvariation in thickness, for the pool builder to ensure that thefinishers are flush against the flange member of the niche.

Another method of building the pool is to provide only one shutter andthe reinforcing bars. The niches are suspended in position and concreteis sprayed onto the shutter, and around the niches, to form the concretewall. The same problem exists for the pool builder when applying thefinishers to ensure they are flush with the flange member of each niche.

A third method of building the pool is to clamp the lining of a flexibleenclosure between two structural layers, typically made of metal,polymer or fibreglass. The two layers also clamp the flange member ofeach niche and apertures are cut into the material at each niche. Afourth method is to form a fibreglass enclosure in which apertures arecut for receiving each niche which is fastened to the fibreglass wall atthe niche flange.

Conventional pool lights do not offer a means for adjusting the distancefrom visible parts of the pool light, such as the flange member, to thewall of the pool to accommodate variation in thickness of the finishers.Furthermore, no pool light presently exists which can be fitted to eachof the four types of pools described above without modification by thepool builder.

Conventional pool lights use one or more separate replaceable bulbs in ahousing. Electrical power is supplied via an insulated cable whichenters the housing from the niche via an aperture. The aperture includesa permanent seal in order to prevent water entering the housing.

The housing is cooled by the water present in the space between theniche and the housing and also by the water in contact with the lens atthe front of the housing. However, there is limited ability for water toflow within the niche. This can cause the accumulation of body fat fromswimmers, which can be a health hazard as it encourages the growth ofbacteria such as legionella.

When it is necessary to replace the bulb, or carry out any othermaintenance to the unit, the housing must be removed from the niche andlifted out of the water. Typically the bulb has a life of around 250 to1,000 hours of use. Removal of the housing typically requires theremoval of a number of screws, which is a difficult task to carry outunderwater, due to a lack of visibility and mobility. The cable istypically of sufficient length between the niche and the housing toallow the maintenance to be carried out at the side of the pool.

An improved type of pool light would comprise a modular unit whichincludes a bulb in a cavity which is enclosed by a permanently sealedbody. When replacement of a bulb for such a unit is necessary the entireunit is replaced. This type of pool light would therefore be disposable.Such a type of pool light would require a wet mateable electricalconnection between the pool light and the power cable provided in theniche. Also, fittings would be required to prevent any maintenance orbulb replacement from being attempted.

Conventional pool lights do not provide this wet mateable connection orsuitable fittings. Such pool lights typically include male connectorswhich permit electrical arcing if the pool light is connected to thepower cable underwater. Also, the male connectors often include a guidepin which is easily damaged.

It is desirable that light from the pool light can project from the sidewall and across at least half the width of a standard training pool, aswell as achieving illumination of the bottom of the pool. In a typicalswimming pool, an individual pool light may be required to illuminate anarea having a length of 6 metres from the unit, a width of 4 metres (2metres either side of the unit) and a depth of 2.4 metres from the unitto the base of the pool. It is undesirable and inefficient for theprojected light to be projected upwards relative to the base of thepool.

Conventional pool lights use a three dimensional parabola shapedreflector to reflect light that is projected from the bulb in adirection towards the rear of the housing. Conventional lens andreflector arrangements are not adapted to direct the radiation of lightso that there is a greater proportion of radiation in a downwardsdirection. Also, the angle of illumination, in the plane of the base ofthe pool, is limited. Conventional lamps do not significantly hinder theradiation of light in an upwards direction. Dark regions can be presentin the pool near to the junction of the base and side walls and at theside walls where the pool lights are situated.

According to the present invention, there is provided an underwater poollight comprising:

-   -   a housing;    -   a lens sealingly fixed to the housing;    -   a light source located within the housing;    -   mounting means for mounting the housing to a niche within or on        a wall of a pool, wherein:    -   the housing includes an integral connector for external        connection to an electrical supply cable, and    -   the pool light includes electrical connection means within the        housing connecting the light source to the integral connector.

Preferably the pool light includes a niche for mounting the housingwithin or on the wall of a pool.

Preferably the connector is wet mateable.

Preferably the connector includes a cable receiving recess, and therecess has a keyed portion which is complementary to a keyed portionprovided at the cable. Preferably the cable receiving recess is formedby a flange projecting from the housing.

Preferably the connector comprises one or more pins projectingexternally from the housing and adapted to engage with one or morecorresponding sockets on the cable. Preferably the pins project into therecess. Preferably a portion of each pin is encased in the housing.

Preferably the connector further comprises one or more sleevesprojecting externally from the housing and at least partiallysurrounding the one or more pins. The sleeves may be formed integrallywith the housing. Preferably the or each sleeve is made of plastic orrubber.

Preferably the mounting means comprises a component of the housingadapted to slideably engage with a component of the niche, such that thedistance between the housing and the niche is selectively adjustable.Preferably the pool light includes clamping means for clamping thecomponent of the housing relative to the component of the niche.

Preferably the mounting means is adapted such that the distance betweenthe housing and the niche is infinitely adjustable over the adjustmentlength.

Preferably the component of the housing comprises one or moreprotrusions provided at the housing and the component of the nichecomprises one or more slots provided at the niche. Preferably threeprotrusions and three slots are provided. Preferably the or eachprotrusion includes a keyed portion which is complementary in profile tothe profile of the slot.

Preferably the clamping means comprises at least one screw fastener.

Preferably the pool light includes a lens and the component of thehousing is provided at a lens holding member.

Preferably the housing includes a collar projecting from a face of thehousing. Preferably the collar has a projecting length of around 50millimetres. The collar provides an edge up to which a pool builder mayapply finishers to the pool wall. The collar may then be trimmed.

Preferably the housing includes one or more cam receiving slots, and thelens includes one or more cammed members for pivotally locating the lensrelative to the lens holding member. Preferably two cammed members areprovided.

Preferably the lens includes fastener locating means and a fastener forfastening the lens to the lens holding member. Preferably the fastenerlocating means comprises a hollow coned protrusion for aligning the lensto a fastener receiving aperture provided at the lens holding member.The cammed members and fastener locating means allow self alignment ofthe lens to the lens holding member.

Preferably the housing includes a lamp enclosure which is sealablyconnected to the lens by a plurality of fasteners. Preferably thehousing includes a trim guard which covers the fasteners to preventunfastening of the fasteners. Preferably the trim guard includes aplurality of pegs which are received in apertures provided at the lens.The trim guard prevents removal of the lens for replacement of the bulbor other maintenance of the pool light.

Preferably the housing includes two or more openings for allowing theflow of water into and out of the niche. Preferably the openings areprovided at the perimeter of the lens. Preferably the openings comprisea number of cut-outs or castellations provided at the perimeter of thelens.

Preferably the niche includes one or more brackets for receiving one ormore fastening rods, such as screwed rod. Preferably the or each bracketis adapted to receive one or more fastening rods of a plurality ofsizes. Preferably the or each bracket is adapted to receive fasteningrods oriented vertically, horizontally, or obliquely relative to thebase of the pool.

Preferably the lens has a first portion adapted to direct lightsubstantially normal to the wall of the pool, and a second portionadapted to direct light substantially parallel to the wall of the pool,and wherein the pool light further comprises:

-   -   a reflector located within the housing and having a first        portion which is substantially parabolic in vertical cross        section and a second portion which is adapted to reflect light        substantially towards the second portion of the lens.

Preferably the second portion of the lens is provided at the internalsurface of the lens. Preferably the second portion of the lens comprisesa plurality of Fresnel members adapted to direct light substantiallyparallel to the wall of the pool. Preferably each Fresnel memberincludes an edge adapted to bend light so that it is substantiallyparallel to the wall of the pool. The second portion of the lens may beadapted to cause diffraction of light in a direction substantiallyparallel to the wall of the pool. The second portion of the lens mayinclude a reflective surface to reflect light in a directionsubstantially parallel to the wall of the pool.

Preferably each Fresnel member is arcuate and substantially concentricabout the light source. Preferably the second portion of the lens isadapted to direct light downwards. Preferably the second portion of thelens is further adapted to direct light substantially horizontally ineach direction.

Preferably the first portion of the reflector is substantially linear inhorizontal cross section.

Preferably the second portion of the reflector has a planar surfaceoriented to reflect light substantially towards the second portion ofthe lens. Preferably the second portion of the reflector is provided atan upper region of the reflector.

Preferably the reflector includes a third portion which is adapted toreflect light substantially towards the second portion of the lens.Preferably the third portion of the reflector has a planar surface.Preferably the third portion of the reflector is provided at each sideof the reflector.

Preferably the pool light further comprises a shading member adapted toinhibit the radiation of light in at least one direction. Preferably theshading member is adapted to inhibit the radiation of light in anupwards direction.

Preferably the shading member is positioned at the external surface ofthe lens. Alternatively the shading member is positioned at the internalsurface of the lens. Preferably the shading member is press fit to thelens or housing.

Preferably the shading member is positioned at an upper portion of thelens relative to the base of the pool. Preferably the shading member issubstantially oval.

An embodiment of the present invention will now be described, by way ofexample only, with reference to the accompanying drawings, in which:

FIG. 1 is a side view of a pool light;

FIG. 2 is a front view of the pool light of FIG. 1;

FIG. 3 is a perspective exploded view of the pool light of FIG. 1;

FIG. 4 is a perspective front view of a lens of the pool light of FIG.1;

FIG. 5 is a perspective rear view of the lens of FIG. 4;

FIG. 6 is diagrammatic side view of the pool light of FIG. 1;

FIG. 7 is the diagrammatic view of FIG. 6 showing the radiation oflight;

FIG. 8 is a diagrammatic plan view of the pool light of FIG. 1;

FIG. 9 is the diagrammatic view of FIG. 8 showing the radiation oflight;

FIG. 10 is a perspective view of a reflector of the pool light of FIG.1;

FIG. 11 is a perspective front view of a bezel of the pool light of FIG.1;

FIG. 12 is a perspective rear view of the bezel of FIG. 11;

FIG. 13 is perspective front view of a niche of the pool light of FIG.1;

FIG. 14 is a perspective rear view of a housing of the pool light ofFIG. 1;

FIG. 15 is a perspective front view of a housing of the pool light ofFIG. 1;

FIG. 16 is a sectional side view of a housing of the pool light of FIG.1;

FIG. 17 is a sectional plan view of a housing of the pool light of FIG.1;

FIG. 18 is a perspective view of a supply cable of the pool light ofFIG. 1;

FIG. 19 is a sectional side view of the pool light of FIG. 1; and

FIG. 20 is a perspective rear view of the niche of FIG. 13.

Referring to FIGS. 1 to 3 there is shown a pool light 10 comprising ahousing 20 which has a opening that is covered by a lens 30. A reflector40 and a light source in the form of two bulbs 50 are housed within thehousing 20. A trim guard 60 is fitted to the lens 30.

The housing includes a lamp enclosure 70 and lens holding member, orbezel 80, which is sealably connected to the lamp enclosure 70 using anumber of gaskets 90.

A collar (not shown) may be provided as projecting from the innercircumference of the lamp enclosure 70. This collar, typically of 50millimetres length, provides an edge up to which a pool builder mayapply finishers to the pool wall. Once the finishers had been applied,the collar may then be trimmed so that its projecting edge is flush withthe pool wall.

The lamp enclosure 70 includes an electrical connector 100 forconnection to a power supply cable 110. Internal wiring (not shown)connects the connector 100 to the two bulbs 50.

FIG. 5 is a rear view of the lens 30. The lens has a first portion 32adapted to direct light in a direction substantially normal to the wallin which the pool light 10 is fitted. This direction is shown in FIG. 1and is denoted as direction ‘A’. The lens 30 also has a second portionwhich comprises a number of Fresnel members 34 which are adapted todirect light substantially parallel to the wall of the pool. Thisdirection may be downwards which is shown in FIGS. 1 and 2 as direction‘B’. The direction of light from the Fresnel members 34 may also behorizontal which is shown in FIG. 2 as direction ‘C’. The direction oflight may also be at an oblique angle lying anywhere between directions‘B’ and ‘C’. The Fresnel members 34 are all provided within a lowerregion of lens 30, and are arcuate and concentric about the bulbs 50.Each Fresnel member 34 includes an edge 36 which is adapted to bendlight so that it is parallel to the pool wall.

Light may reach the lens 30 directly from the bulbs 50 or it may bereflected from the reflector 40. The reflector 40 is shown in FIG. 10,and its sectional profile is shown in FIGS. 6 to 9. The reflector 40 hasa first portion 42 which is substantially parabolic in vertical crosssection and so reflects light in a direction substantially normal to thepool wall. The reflector 40 also has a second portion 44 which has aplaner surface and is oriented to reflect light substantially towardsthe Fresnel members 34. FIG. 7 shows that a substantial amount of lightis radiated in a direction normal to the pool wall. A significantproportion of light is also radiated downwards.

As shown in FIG. 8, the first portion of the reflector is linear inhorizontal cross section, rather than parabolic. The reflector 40 alsoincludes a third portion 46 which has a planar surface and is orientedto direct light to the Fresnel members 34 so that the light is directedhorizontally and parallel to the wall of the pool. The radiation oflight can be seen in FIG. 9, and it can be seen that a significantproportion of light is radiated in a substantially horizontal direction.

It is to be understood that the reflector 40 and Fresnel members 34co-operate to provide a significant portion of light being directed in adirection parallel to the pool wall and that, if either feature wereused individually, the effect would not be significant.

The reflector is typically made from aluminium. FIG. 10 shows that an‘S’ shape is stamped through the reflector wall at each side at aposition near to the bulbs 50. This allows folding of the materialwithin the ‘S’ shape to produce two legs to hold each bulb 50 whileproviding an aperture for receiving each bulb 50 and allowing access toelectrical wiring.

As seen in FIG. 2, the trim guard 60 includes a shading member 62positioned at an upper region of the lens 30. The shading member 62 isoval and opaque and so inhibits the radiation of light in an upwardsdirection.

Referring to FIG. 4, the trim guard 60 is fitted to the lens 30 usingalternate holes 38 provided in the lens 30. The rear of the trim guard60 includes pegs (not shown) for press fitting into the holes 38. Theremaining holes 39 of the lens 30 are used for connection of the lens 32to the lamp enclosure 70.

The pool light 10 includes a niche 120 for mounting the pool light 10within the wall of the pool. Mounting means are provided for mountingthe housing 20 to the niche 120. The mounting means comprises acomponent of the housing, in the form of three protrusions 82 providedat the rear of the bezel 80, which are adapted to slidably engage with acomponent of the niche, in the form of corresponding slots 122 providedat the niche 120. The bezel 80 and niche 120 are shown in FIGS. 11 to13. The mounting means allows the distance between the housing 20 andniche 120 to be selectively adjusted. Clamping means, in the form ofscrew fasteners (not shown) are provided for clamping the protrusions 82at the selected position in the slots 122.

The bezel 80 includes two cam receiving slots 84 (as shown in FIG. 11)for receiving the cammed members 86 provided at the lens 30 (as shown inFIG. 4). The lens 30 may conveniently be fitted to the bezel 80 bylocating the cammed members 86 in the cam receiving slots 84 andpivoting the upper region of the lens 30 towards the bezel 80. The lens30 includes fastener locating means in the form of a hollow conedprotrusion 24 provided at the rear of the lens 30. The coned profile ofthe protrusion 24 assists to align the protrusion 24 in a fastenerreceiving aperture 88. A fastener such as a screw (not shown) may beinserted through the coned protrusion 24 and screwed within the aperture88 to hold the lens 30 to the bezel 80. The cammed members 86, fastenerlocating means, and the use of only one fastener allow easier aligningand fastening of the lens 30 to the bezel 80.

FIG. 4 shows that the lens 30 includes a number of openings orcastlations 26 provided at the perimeter of the lens 30. Thesecastlations 26 allow the flow of water into and out of the niche 120.

FIGS. 14 to 17 show the electrical connector 100 of the housing 20 forconnection to a power supply cable 110, a portion of which is shown inFIG. 18. The connector is wet mateable in the sense that the pool light10 may be connected to the power cable 110 under water.

The connector 100 includes two terminal pins 106, each partiallyenclosed by a sleeve 108 formed from an electrically non-conductingmaterial, such as plastic. The pins 106 and sleeves 108 are permanentlyfixed within apertures 109 provided in the housing 20. Any suitablefixing means can be used providing that water is not able to enter thehousing 20 via the apertures. In the illustrated embodiment, the pins106 and sleeves 108 are moulded into the housing. Wiring (not shown) isused to connect the exposed end of each pin 106 to the bulbs 50.

The supply cable 110 includes two sockets 114 which receive the otherend of the pins 106 within the sleeves 108 to form an electricalconnection when the pins 106 have been fully received. The close fittingof the sleeves 108 to the sockets 114 causes water to be expelled fromthe sockets 114. The other end of the cable 110 is permanently fixed toa second connector 130 provided at one of two cable entry ports 132provided in the niche 120. A further supply cable (not shown) connectsthe second connector 130 to the power supply.

The connector 100 includes a cable receiving recess 102. This recess 102includes a keyed portion 104 which is complementary to a keyed portion112 of the cable 110. These keyed portions 104, 112 permit insertion ofthe cable 110 into the recess 102 in one orientation only, therebyensuring correct insertion of the cable 110.

FIG. 19 shows the pool light 10 within the niche 120. The pool light 10can be removed a short distance from the niche 120 and then disconnectedfrom the supply cable 110 while still underwater. Therefore, only ashort length of cable 110 need be accommodated between the housing 20and niche 120. The L shape of one end of the cable 110 also assists inaccommodating the cable 110.

FIG. 20 shows that the niche 120 includes a number of brackets 124 forreceiving fastening rods, such as screwed rod 126. The screwed rod 126is typically of the standard size such as M6 or M8, and the brackets areadapted to receive more than one size of screwed rod 126. The brackets124 are adapted to receive screwed rod 126 which is vertically orhorizontally oriented. This allows the vertical position of the poollight 10 to be set during installation.

The present invention may be used for any of the four methods of poolbuilding without any further modification.

Various modifications and improvements can be made without departingfrom the scope of the present invention.

1-29. (canceled)
 30. An underwater pool light comprising: a housing; a light source located within the housing; a lens sealingly connected to the housing by a plurality of fasteners; and a guard member adapted to prevent unfastening of at least one of the plurality of fasteners such that the light source is enclosed within a permanently sealed body.
 31. An underwater pool light as claimed in claim 30, wherein the guard member includes a plurality of protrusions which are receivable in apertures provided at the lens.
 32. An underwater pool light as claimed in claim 30, wherein the housing includes an integral connector for external connection to an electrical supply cable, and the pool light includes electrical connection means within the housing connecting the light source to the integral connector.
 33. An underwater pool light as claimed in claim 32, wherein the connector is wet mateable.
 34. An underwater pool light as claimed in claim 32, wherein the connector includes a cable receiving recess, and wherein the recess has a keyed portion which is complementary to a keyed portion provided at the cable.
 35. An underwater pool light as claimed in claim 32, wherein the connector comprises at least two pins projecting externally from the housing and adapted to engage with at least two corresponding sockets on the cable.
 36. An underwater pool light as claimed in claim 32, wherein the connector further comprises at least two sleeves projecting externally from the housing and at least partially surrounding the at least two pins.
 37. An underwater pool light as claimed in claim 36, wherein each sleeve is made of plastic.
 38. An underwater pool light as claimed in claim 36, wherein each sleeve is integral with the housing.
 39. An underwater pool light as claimed in claim 30, including a niche and mounting means for mounting the housing to the niche.
 40. An underwater pool light as claimed in claim 39, wherein the mounting means comprises a component of the housing adapted to slideably engage with a component of the niche, such that the distance between the housing and the niche is selectively adjustable.
 41. An underwater pool light as claimed in claim 40, further including clamping means for clamping the component of the housing relative to the component of the niche.
 42. An underwater pool light as claimed in claim 41, wherein the clamping means comprises at least one screw fastener.
 43. An underwater pool light as claimed in claim 40, wherein the mounting means is adapted such that the distance between the housing and the niche is infinitely adjustable over the adjustment length.
 44. An underwater pool light as claimed in claim 40, wherein the component of the housing comprises at least one protrusion provided at the housing and the component of the niche comprises at least one slot provided at the niche.
 45. An underwater pool light as claimed in claim 40, wherein the component of the housing is provided at a lens holding member.
 46. An underwater pool light as claimed in claim 45, wherein the housing includes at least one cam receiving slot, and wherein the lens includes at least one cammed member for pivotally locating the lens relative to the lens holding member.
 47. An underwater pool light as claimed in claim 45, wherein the lens includes fastener locating means and a fastener for fastening the lens to the lens holding member.
 48. An underwater pool light as claimed in claim 47, wherein the fastener locating means comprises a hollow coned protrusion for aligning the lens to a fastener receiving aperture provided at the lens holding member.
 49. An underwater pool light as claimed in claim 39, wherein the housing includes a collar projecting from a face of the housing.
 50. An underwater pool light as claimed in claim 39, including at least two openings for allowing the flow of water into and out of the niche.
 51. An underwater pool light as claimed in claim 50, wherein the openings comprise a number of castellations provided at the perimeter of the lens.
 52. An underwater pool light as claimed in claim 39, wherein the niche includes at least one bracket for receiving at least one fastening rod.
 53. An underwater pool light as claimed in claim 52, wherein each bracket is adapted to receive at least one fastening rod of a plurality of sizes.
 54. An underwater pool light as claimed in claim 52, wherein each bracket is adapted t receive fastening rods oriented vertically relative to the base of the pool.
 55. An underwater pool light as claimed in claim 52, wherein each bracket is adapted to receive fastening rods oriented horizontally relative to the base of the pool.
 56. An underwater pool light as claimed in claim 52, wherein each bracket is adapted to receive fastening rods oriented obliquely relative to the base of the pool.
 57. An underwater pool light as claimed in claim 30, wherein the lens has a first portion adapted to direct light substantially normal to the wall of the pool, and a second portion adapted to direct light substantially parallel to the wall of the pool, and wherein the pool light further comprises: a reflector located within the housing and having a first portion which is substantially parabolic in vertical cross section and a second portion which is adapted to reflect light substantially towards the second portion of the lens.
 58. An underwater pool light as claimed in claim 57, wherein the second portion of the lens is provided at the internal surface of the lens.
 59. An underwater pool light as claimed in claim 57, wherein the second portion of the lens comprises a plurality of Fresnel members adapted to direct light substantially parallel to the wall of the pool.
 60. An underwater pool light as claimed in claim 59, wherein each Fresnel member is arcuate and substantially concentric about the light source.
 61. An underwater pool light as claimed in claim 57, wherein the reflector includes a third portion which is adapted to reflect light substantially towards the second portion of the lens.
 62. An underwater pool light as claimed in claim 57, further comprising a shading member adapted to inhibit the radiation of light in at least one direction. 